This document provides summaries of two construction projects completed by SAM INDIA: the Tirupati International Airport and the Palm Olympia residential development in Noida. For the airport project, it describes the client, construction equipment used including boom lifters, structural details of the building, and materials like steel, glass and aluminum. For the Palm Olympia project, it outlines the client, use of concrete mixing trucks and tower cranes, concrete production process, reinforcement details, and safety measures on site. The intern gained exposure to various construction aspects during the 4-week internship.

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INDUSTRIAL INTERNSHIP
BY
VIBHOR BANSAL
(13BCL0143)
SAM INDIA BUILT WELL PVT. LTD.
FROM
1. Tirupati International Airport
2. Noida Township
VIT UNIVERSITY
VELLORE – 632 014, TAMILNADU
Submitted to
VIT University
April 2016
CERTIFICATE

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It is Certified that this is a Bonafide record of work done by
Mr.VIBHOR BANSAL (Reg. No. 13BCL0143)of Civil Engineering
(Batch 2013, VIT University, Vellore) during summer 2015 at SAM
INDIABUILT WELL PVT. LTD. . This record is submitted for the
Internship Review Examination.
Authorised Signatory
CONTENT

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PROJECT 1 : Tirupati International Airport (AAI)
1.1 Introduction………………………………
1.2 Client and Contractor……………………..
1.3 Construction Equipments…………………..
1.4 Structural Highlights.………
1.5 Roof..…………
1.6 Glazing………………
1.7 Roads..…………
1.8 ACP………………
PROJECT 2 : Palm Olympia, Noida
2.1 Introduction.........................................
2.2 Client and Contractor……………………..
2.3 Construction Equipments…………………..
2.4 Production of concrete....................
2.5 Reinforcement..........................
2.6 CLC bricks…………………..
2.7 Foundation …………………..
2.8 Safety…………………..

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Project at a glance
Conclusion
ACKNOWLEDGEMENT

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I express my sincere thanks toMr. Arvind Goel, Managing
Director,SAM INDIA BUILT WELL PVT. LTD. for all the facilities
provided for completion of four weeks of the Industrial Training and
for his valuable guidance and inspiration.
Last but not the least; I would like to thank my guide “Prof. Sairam
V” for his kind support and guidance.
Tirupati International Airport

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1.1 INTRODUCTION
1. Tirupati Airport, is a public airport located at Renigunta, a suburb of Tirupati in
the state ofAndhra Pradesh, India. The airport is located 14 km (8.7 mi) away
from Tirupati and 39 km (24 mi) fromVenkateswara Temple, Tirumala.
2. Tirupati airport was established in the year 1976. Then Prime Minister of India, P.
V. Narasimha Rao laid the foundation stone for a new terminal building, run way
expansion and a radio tower in 1993 at a cost of ₹11 crore.
3. The upgraded airport was opened for passenger traffic in 1999 by then Prime
Minister of India Atal Bihari Vajpayee.
4. A new integrated terminal referred to as Garuda Terminal was constructed
besides the existing domestic terminal in an area of 16,500 square metres
(178,000 sq ft) at a cost of ₹175 crore.
5. The terminal can handle 500 domestic and 200 International Passengers at a
time.
6. Construction began in 2012,[5] and the terminal was inaugurated on 22 October
2015 by present Prime Minister of India, Narendra Modi.

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1.2 CLIENT AND CONTRACTOR
 Client : Airport Authority of India (AAI)
 Contractor : SAM INDIA
1.3 CONSTRUCTION EQUIPMENTS
In this project, there are many construction equipments used for making concrete, to transfer
materials, etc.
1.3.1 BOOM LIFTER
A boom lifter is a mechanical device used to provide temporary access for people or equipment to
inaccessible areas, usually at height. There are distinct types of mechanized access platforms and
the individual types may also be known as a "cherry picker" or a "scissor lift".
They are generally used for temporary, flexible access purposes such
as maintenance and construction work or by firefighters foremergency access, which distinguishes
them from permanent access equipment such as elevators. They are designed to lift limited
weights — usually less than a ton, although some have a higher safe working load (SWL)[1]
—
distinguishing them from most types of cranes. They are usually capable of being set up and
operated by a single person.
1.4 Structural Highlights
 The structure of the International Airport os completely a green building design .
 The major things used in the construction is steel, glass and aluminum casings.
 The structure has a combination of combined footing and isolated on a raft type
foundation spread over all.
 The structure has 27 columns completely made of steel supported by a base plate.
 Each column is made up of steel coated with fire resistant paint . No RCC columns
are used whatsoever.
 The columns are hollow with a thickness of 25mm.

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 The whole steel structure is supported by 27 hollow steel columns . The four legs
merge on top of the column on top of which truss and purlins are supported.
 The whole building plan has been divided into different zones for aiding the
construction purpose. At every zone a column is present.
1.5ROOF
It has been done in different layers
 Bottom sheet with perforations(0.5mm thick)
 Acoustic paper- for sound proofing. Not woven and 0.1mm thick
 Rock Wool- density= 48kg/m3 and thickness= 50mm
 Rock wool with aluminum foil
 Vapour barrier- polythene – 400 gauge over insulation
 Top Sheet- thickness is 0.6mm and yield strength is 300mpa
1.6 GLAZING
The whole building has glazing overall with toughened glass.
DGU - Double glass units.
The glazing is supported by aluminum frames of bolts with 4 bolts in mullion and 7 bolts in
transom.
For better appearance the screws are having a cap called bins.
DGU – there are two glasses and in between is vacuum and is sealed using vacuum.

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1.7 ROADS
Most of the roads are cemented and are made from concrete.
Since the soil is clayey, the layers are layered as follows with a road width of 7.5m and
depth of excavation as 1.2m.
The base is good earth , then morram , then wet mix maccadum and then pqc top.
The road is bounded by curved stone ie 15cm above road.
The parking area has grass track pavers and CC pavers.
1.8 ACP(ALUMINUM COMPOSITE PANEL)
It is mostly used for decorative purpose
It is not corrosive.
Can be molded into required shape.
Eg according to site it is used outside below roofs to get a catchy look.
The two adjacent plates are kept 6 inches apart and joint using steel rods. The steel is
joined to M-S purlins which are extended from truss. The steel joint is filled with black
silicon to get an even look.
PALM OLYMPIA, NOIDA

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2.1 INTRODUCTION
 Nestled amidst 25 acres of lush landscaped greenery, sheltering you from the
bustle of the city is Palm Olympia. These exclusive premium residences of Palm
Olympia are flanked of acres pristine natural of beauty. Its only here that you’d
get to truly experience, the joys of living in the midst of architectural and
infrastructural haven surrounded by lush greenery.
 Experience the Best of Both Worlds
The unforgettable view of open sky, beautiful landscape, wide pathways, tree-
lined well lit roads and illuminated fountains, where every morning sunlight peeps
in and where moon-lit night brings relaxation for life in your spacious apartment
accentuates the idyllic old world charm of the complex. However, you will never
feel cut off from civilization, as Palm Olympia is a part of the meticulously
planned urban destination of Greater Noida (West) that boasts of one of most
enviable infrastructures in Delhi and NCR.
 Architectural Planning
The architectural planning of Palm Olympia is such that we have successfully
ensured that all our residents get to experience nature in all its glory. All our
apartment complexes have been designed to maximize the panoramic views.
The well laid out units and generous balconies promise breathtaking views and
healthful gulps of fresh air.
Here you can design your own version of the Hanging Gardens, install mini
fountains or build a playpen for your toddler – let your imagination run riot without
ever worrying about space.
It’s only here that you would experience the perfect union of natural bounties with
the best in its class architecture.
 At Play with Nature
Bedazzling your senses with a riot of colors are exotic seasonal blooms that grow
all around the complex. Amidst the never ending greenery, through trees, ponds,
flower gardens and bamboo groves is the carefully laid jogging track inspiring
you to completely lose all track of time.
 Excellent Outdoor and Indoor Sports Facilities
If you had always wished to live in a locality that took sports seriously, you will be
delighted with the two massive sports corridors within the township, giving you
ample opportunities to shoot the hoops, perfect your drop shot or take a shy at
the stumps.

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 Convenience at Your Doorstep
With resort style luxury and convenience beckoning you from all sides, your life
at Palm Olympia will smooth and free from daily hassles. Not only are you
guaranteed of world class infrastructure with abundant power and water supply
and backup, we have taken care of all your daily needs and requirements:
 Clutter free, Peaceful and Perfectly Safe
Palm Olympia’s main entrance with its straight wide roads, manicured lawns and
shimmering pools of water have been designed to give you a five star déjà vu
every time you drive through the stately gates of the complex.
No honking, switching lanes or any chance of rash driving as our wide straight
roads are always perfectly safe for pedestrians. And with more than 80 percent
open to the sky, congestion will never become a part of Palm Olympia’s
dictionary.

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2.2 CLIENT AND CONTRACTOR
 Client : SAM INDIA
2.3 CONSTRUCTION EQUIPMENTS
In this project, there are many construction equipments used for making concrete, to transfer
materials, etc.
1.3.1 Ready Mix Concrete:
Ready mixed refers to concrete that is batched for delivery from a central plant instead
of being mixed on the job site. Each batch of ready-mixed concrete is tailor-made
according to the specifics of the contractor and is delivered to the contractor in a plastic
condition, usually in the cylindrical trucks often known as "cement mixers."
Ready-mixed concrete is particularly advantageous when small quantities of concrete or
intermittent placing of concrete are required. Ready-mixed concrete is also ideal for
large jobs where space is limited and there is little room for a mixing plant and
aggregate stockpiles.
1.3.2Transit Mixture:
Transit Mixer is a strong well - designed piece of equipment meant for
transporting concrete / mortar from concrete batching plant directly to the
place where it is to be poured. It has a wide range of application specially for
mass concreting works like Construction of Canals, Bridges, Highways,
Dams, Multistoried & Industrial Buildings, Factories, Airports and for Ready
Mixed Concrete Works
1.3.3 Fixed Tower Crane :
Tower cranes are a modern form of balance crane that consist of the same
basic parts. Fixed to the ground on a concrete slab (and sometimes attached
to the sides of structures as well), tower cranes often give the best

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combination of height and lifting capacity and are used in the construction of
tall buildings. The base is then attached to the mast which gives the crane
its height. Further the mast is attached to the slewing unit (gear and motor)
that allows the crane to rotate. On top of the slewing unit there are three
main parts which are: the long horizontal jib (working arm), shorter counter-
jib, and the operators cab.
In order to hook and unhook the loads, the operator usually works in
conjunction with a signaller (known as a 'dogger', 'rigger' or 'swamper').
They are most often in radio contact, and always use hand signals. The
rigger or dogger directs the schedule of lifts for the crane, and is responsible
for the safety of the rigging and loads.
1.3.4 Concrete Vibrators :
Concrete vibrators consolidate freshly poured concrete so that trapped air and excess water are
released and the concrete settles firmly in place in the formwork. Improper consolidation of
concrete can cause product defects, compromise the concrete strength, and produce surface
blemishes such as bug holes and honeycombing. An internal concrete vibrator is a steel cylinder
about the size of the handle of a baseball bat, with a hose or electrical cord attached to one end.
The vibrator head is immersed in the wet concrete.
In the site the vibrator was used to make checkered tiles.
Checkered tiles
Size -300*300*40 mm
First in mold the colored concrete is poured mixed with white cement till 7mm height and
then normal concrete poured for rest 33mm height. The mold is passed on table vibrator.
Final setting time is 24 hrs.
Mold is removed and curing is done for 7-10 days.

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2.4 PRODUCTION OF CONCRETE
1.4.1 Concrete Ingredients :
Source of coarse & fine aggregates shall be approved by contractor engineers before any
activities like starting of mix design etc started & all other materials would be supplied as per
approved make. Brand of Cement and admixtures are as per the contract.
1.4.2 Cement :
The cement used is Ordinary Portland cement (OPC) of GRADE 43.
1.4.3 Coarse Aggregate :
The maximum size of coarse aggregate shall be such that the concrete can be placed without
difficulty so as to surround all reinforcement thoroughly and fill the corners of formwork.
1.4.4 Fine Aggregate :

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The fine aggregate shall be river sand, normal sand,.
1.4.5 Water:
Water to be used in the works shall be portable water and free from deleterious materials.
1.4.6 Admixtures:
Admixtures used for setting time and also for other purposes. For different work we used
different admixtures.
2.5 REINFORCEMENT
 Came to know about different types of reinforcement.
 We saw about the different lappings in reinforcement. Came to know about main
and secondary rings.
 Bar bending schedule calculation
We learnt all the necessary concepts.
Eg calculations
Substrut=5000-2(50)+2(300)-6d
Nos. = 10000/200
=50+1=51
Let d=6
 Covers – may vary according to column, beam and slab.
 Different types of rings and their calculations
Eg
L=600-2(40)=520

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B=2(l+6)+16d
=2(520+220)+16*8
2.6CLC Bricks
Today we learnt and practically analyzed the manufacturing of CLC bricks.
CLC- cellular light weight concrete bricks
It is made up of cement and fly ash (1:2)
Primary mix- fly ash +water
Secondary mix- cement + accelerator + foaming agent
The mixture is put in molds and initial setting is allowed. Then it is demolded and cut into
required shape and sizes. Then steam curing is done at 70-80 degree for 7-8 hours.
Density of the CLC brick comes out to be 800kg/m3.
Strength of clc bricks is 3.4-3.5mpa, which is less but it is no problem as these are filler
walls that is building is supported on columns and not on walls.
Drawbacks-use of less mortar because size of bricks is large and cracks might occur.
Advantages-
 Fire resistance
 Sound proof
 Water resistant
2.7FOUNDATION
 We started on foundations .
 Chair- to keep the upper reinforcement in place.
 When there is column only lower reinforcement is required and when there is
empty space only lower reinforcement is required.
 Footing is cast using shuttering. After one day shuttering is removed and curing is
started.

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Layout of column
 First a small 50mm part is cast for funneling towards center of column on the
footing. Then the shuttering is placed around the column. Concrete is poured using
crane and bucket. Cover blocks are used and are placed around the steel rods
before the shuttering is placed. It prevents the shuttering to tilt and damage the
column.
 The column is first casted to a height of 2.9m and the other .6m is casted.
2.8SAFETY
Safety is defined as to protect from accident, injury, damage from material, machinery, etc.
SAFETY = Stay Alert For Every Task You Do
Walking in middle of roads.
Don’t walk on edges.
Look all sides and above before entering and leaving a building.
Some personal protective equipments (PPE): provided by site
 Helmet
 Goggles

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 Safety Belt
 Hand Gloves
PROJECT AT A GLANCE
CONCLUSION:-
It was a wonderful learning experience at SAM INDIA for Four Weeks. I gained a
lot of insight regarding almost every aspect of site. I was given exposure in almost
all the departments at the site, but I had liked to highlight the areas of safety, quality
management, material management and execution.

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I hope this experience will surely help me in my future and also in shaping my
career.

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